Topic: Plastikjock's CB550 Caf'

[plastikjock]

I like this section, so I thought I'd join in:


Item picture on Ebay


Mock up with '78 tank


Current State - with k0 tank


Got the fork legs now off a cb750f, I'm hoping there not too long, as you can see I've put them through the triples a bit. They are angled further forward 'cause there's no headset in there yet. Also they are fully extended on the sidestand (centrestand in bin).

I've welded a piece in the back of the tank, to fill the large gap left without the standard seat.

Just been messing around with exhaust. Motad silencer was shot, so I've shortened the headers (approx 4") and spliced a piece of tube in the end to fit the new can. Only tacked in place at moment as I ran out of gas.

 

[rlarkin70]

nice work, looks good. I like the fiberglass seat/tail...is that a light I see in the one photo?

-Ron

[plastikjock]

Thanks.

Led stop/tail light unit is like this:

http://www.perei.co.uk/product.asp?strareano=PRODUCTCATEGORY_2_14&intelement=261

Got a taper headset today, so bikes now in bits again to fit that. £20 posted, arrived in two days.

http://shop.marksman-ind.com/steering-kit-22-1011-1304-p.asp

Looks good, 2xbearings, 2xsimple seal rings, will fit tomorrow.

 

[lentobensa]

let us know about the tail light - mostly curious about its brightness - safety is an issue with all the crazy cagers

[plastikjock]

Now I have a 'complete' bike, but I don't like the angle that it sits at on the side stand, so......................

I made myself a trackstand. Took a while sorting out the lean angle, but got there in the end. The bike now sits vertically. I might even throw some paint at it!






Here's what I've been messing with today:



Got some 5 & 9.5mm cobalt drills on order. I'm gonna print out the layout onto A3 paper (it just fits). Then cut out 'rotor' and glue it to the actual rotor in line with the rivets. Then centre pop all the holes and get drillin'.

 

[FunJimmy]

Lookin good. I really like that track stand.
Hope you don't mind if I copy it.

Thanks Mate
Jimmy

[Head]

Looking good, keep the pic's coming when you can      head

[plastikjock]

Thanks for the encouragement.

Funjimmy - copy trackstand by all means. The one modification I would make to it if I was making it again, would be to 'splay' the legs a little. With them coming straight down it does wobble slightly (so does my shed floor though). However dealing with single angle cuts was tough enough on my brain!

[plastikjock]

I got a pillar drill a while ago and was dying to drill something:



Totally aesthetic, I know, but I thing drilled drums look ace.

Spent an hour or so last night, tidying up the tank. Sanding filler seems to be a never ending job, always discovering another little blemish that needs filling. Finally think I have finished. When I did my Vespa it seemed to take weeks of filling, I hate bodywork. Only got the seat and tank to sort out this time.

I played around with my rotor design again:


5 hole curve


6 hole curve

 

[FunJimmy]

Spent an hour or so last night, tidying up the tank. Sanding filler seems to be a never ending job, always discovering another little blemish that needs filling. Finally think I have finished. When I did my Vespa it seemed to take weeks of filling, I hate bodywork.

I know exactly how you feel. Bodywork SUCKS! LOL

The drill patterns look great. Good luck with it.

Cheers
Jimmy

[Head]

How much does it cost for the full time pit crew?  They look like they are having fun.   
Head

[plastikjock]

Re fulltime pit crew cost - a lot, but the boy's welding is coming on and you should see the girl with an angle grinder, it's a sight to behold. 



Centre popped holes through cad drawing glued to disc. Pilot drilled 5mm, then wacked the 9.5mm through the lot, used some Trefolex (duck#$%*) with the big drill, took about half an hour. Both drill bits still sharp afterwards - easy.

 

[matt365]

Did you use a drill press, or a hand drill?

[plastikjock]

matt365- I used my Drill Press. Drills lovely parallel holes, also you can dial in the cutting speed optimum for you drill and material.

It was cheap as well, £50 in sale at B&Q, stands nearly 1metre tall.

http://www.diy.com/diy/jsp/bq/nav/skins/popups/scene7.jsp?skuId=9677249

[plastikjock]

Small bit of progress made, I have been rebuilding vespa engine for brother in law - but did get some funds for this machine. However I'm gonna require some tank dents for them to clear, I may shift the tank back a little as well.

Got some clip on bars, with controls, clutch lever, throttle & master cylinder all in one Ebay sale, all from an FZR250. I had none of these so this was a good buy.

Tried to get the engine running the other week. Fired, but only on easystart. Stripped and cleaned carbs, 3x blocked jets, but overall good compared to some of the gunk seen elsewhere on this forum.

And today........

http://s74.photobucket.com:80/albums/i245/plastikjock/?action=view&current=P4100057.flv

The cameraman was sacked shortly afterwards.

 

[Sheik Yerbouti]

Hah, it sounds great. I say give the cameraman a second chance.

[tjf]

Chamfer the holes on both sides or the rotor WILL crack.  I know because Ive done the drill press rotor before... with varying levels of results.  it looks nice though

[plastikjock]

Thanks for tip.

Now I have another predicament though, I have cb750f forks and calipers. They actually line up pretty well, only about 1mm out, insert spacer (washer) job done. However the disc diameter is 10mm bigger on the discs I have. Nice easy machine job on a big lathe, but it will end up half way through the outside row of holes. So I'm looking for another disc or discs.

[plastikjock]

Made a bit more progress. Welded in rear frame hoop, cut seat down further to suit. Made rearset mounts & fitted.







My next job is to attempt some tank bashing, at the moment I have limited steering with those bars. I will try to hook up those rearsets.

 

[plastikjock]

Not done anything for ages, too cold. But I've cleared my shed out today so I took some pictures while it was outside.

Since I last posted: I have partially made some rearsets. I have made the toe pegs the same size as the kickstart end, so that I can fit the rubbers from them for the appearance of a factory item (made on a Friday afternoon, by the apprentice).

I have got a front mudguard, modified it to fit and strengthened its fixing points, which I had to move anyway.

Bashed some dents in tank.

Trial fitted the calipers.

I have blasted and polished my controls.

Fitted headlamp.

Bought some cheap air filters, not sure how long they will last.


I am waiting delivery from David Silver various new bits: Tappet covers, kickstart rubbers, chain and points cover. Hopefully when I get them I will have some new enthusiasm to carry on.


 

[greenjeans]

Lookin really good, mind sharing how you bent the frame loop & what kind of tubing that you used ?

[plastikjock]

Cheers, find some electrical contractors that install conduit. 1" diameter steel conduit bent by hand on there mandrel thing. Diameter slightly too small, but with a couple of wacks in the right places was able to line up with existing frame tubes. Then I fitted smaller dia. conduit inside so that it remained straight while I welded it. There is also a cross member between the shock mounts which the seat sits on and another piece at the front, which tidies up the tank mount bit. One day the battery will sit at the back and all the electrics in the aluminium tray under seat.




 

[greenjeans]

conduit.....never thought of that.   I actually have one of those benders that I bought at a garage sale a few years back....
That sounds like it might just be perfect for a seat pan I'm trying to build.

Thanks for the tip  &  keep the pics coming.   That's going to be a sweeet ride when you're done.  I've always loved the looks
of those 550's with the electrics hidden etc.   Always makes them look soooo quick and fun to ride.

[Joksa]

Since your fork tubes are already higher than the top yoke, why not flip it around (and hide also the original bar mounts at the same time).

[plastikjock]

Haven't decided what to do with tree's yet, I would like them to be smooth, but not sure which method to use to fill holes after handlebar mounts are removed.

One of my fork stantions has a dent so I will have to address them anyway. I want some Cycle X http://www.cyclexchange.net/Honda%20Cafe%20Page.htm -2 fork tubes. Should have bought them ages ago when the pound was stronger, they were only £75 last summer now they are £101 before postage from US. I might look into rechroming my tubes and get them shortened by 2" while they are at it, still gonna cost me around £100.